Packaging member

ABSTRACT

A packaging member for protecting an edge of an article includes a member having a first leg and a second leg disposed at a predetermined angle to each other along a junction. At least two material plies are integrally connected along the junction. Each of the at least two material plies define a bend having a first width and a second width, wherein the first width and second width define different magnitudes.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application is a continuation of U.S. patent application Ser. No. 11/851,825 filed on Sep. 7, 2007, and entitled “Packaging Member”, the disclosure of which is hereby incorporated by reference herein in its entirety and made part of the present U.S. utility patent application for all purposes.

BACKGROUND OF THE INVENTION

The present invention relates generally to packaging members, and more particularly to laminated paperboard packaging members for enclosing a product.

Elongated products, especially those having small cross sectional areas typically require special packaging containers for protection from damage while the products are transported. Tubular containers are well known for this purpose. However, tubular containers are expensive to manufacture and require the product be directed into one end of the container, which is cumbersome, and further requires the “packaging loading area” for the product into the packaging member to be at least twice the length of the product. In addition, transport of already formed empty tubular containers is costly.

Another type of packaging member, typically an angle member, protects the edges of larger articles, such as appliances. It is desirable to reduce the costs of these packaging members without adversely affecting their function.

Thus, there is a need for a packaging member which may be used to protect elongated products that can be more cheaply transported. Similarly, there is a need for a packaging member, which may be used to protect article edges, that is less expensive to manufacture, while maintaining structural rigidity.

SUMMARY OF THE INVENTION

The present invention relates to a packaging member for securing an article including a preformed laminated paperboard member having a preselected length. The member has a first leg and a second leg forming a substantially L-shaped cross section of rigid construction across the length of the member. The first leg has at least one substantially parallel discontinuity formed substantially along the preselected length of the member, each discontinuity forming at least two adjacent leg portions connected together. In response to the first leg and the second leg being directed toward each other, one of the at least two adjacent leg portions is directed into contact with the second leg to define an enclosed region for securing an article therein. The packaging member can be nested with additional packaging members in an unassembled position and corresponding surfaces of first and second legs of adjacent nested packaging members can be maintained in abutting contact.

In another embodiment, the present invention relates to a packaging member for protecting an edge of an article. The packaging member includes a first leg and a second leg disposed at a predetermined angle to each other along a junction. At least two different material plies are integrally connected along the junction. Each of the material plies defines a bend having a first width and a second width, wherein the first width and second width defining different magnitudes.

In still another embodiment, the present invention relates to a packaging member for securing an article. The packaging member includes a preformed laminated paperboard member having a preselected length. The member has a first leg and a second leg forming a substantially L-shaped cross section of rigid construction across the length of the member. The first leg has at least two substantially parallel discontinuities formed substantially along the preselected length of the member. The at least two discontinuities form at least three adjacent leg portions connected together. In response to the first leg and the second leg being directed toward each other, a distance between the first and second leg is defined. Multiple packaging members can be nested in an unassembled position, and corresponding surfaces of first and second legs of adjacent nested packaging members can be maintained in abutting contact.

In yet another embodiment, the present invention relates to a packaging member for securing an article. The packaging member includes a preformed laminated paperboard member having a preselected length, the member having a first leg and a second leg forming a substantially L-shaped cross section of rigid construction across the length of the member. The first leg has a substantially parallel discontinuity formed substantially along the preselected length of the member. The discontinuity forms two adjacent leg portions forming an angled joint in the first leg in response to the first leg and the second leg being directed toward each other to define a distance between the first and second leg. A first group of multiple packaging members can be nested in an unassembled position, and corresponding surfaces of first and second legs of adjacent nested packaging members can be maintained in abutting contact.

One advantage of the present invention is that adjacent packaging members can fully nest with each other, minimizing the space required for transport.

Another advantage of the present invention is that the packaging member is inexpensive to manufacture due to savings of material costs.

Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a packaging member.

FIG. 2 is a cross sectional view of the packaging member taken along line 2-2 from FIG. 1.

FIG. 3 is an end view of the packaging member in an unassembled position.

FIG. 4 is an end view of a further embodiment of the packaging member in an unassembled position.

FIG. 5 is an exploded end view of a still further embodiment of the packaging member in an unassembled position.

FIG. 6 is an end view of another embodiment of a packaging member.

FIG. 7 is an end view of still another embodiment of a packaging member.

FIG. 8 is an enlarged partial end view of a corner from an embodiment of the packaging member.

FIG. 9 is an end view of an embodiment of a packaging member.

FIG. 9A is an end view of a further embodiment of a packaging member.

FIG. 10 is an exploded end view of a still further embodiment of a packaging member.

FIGS. 11-14 are additional embodiments of a packaging member.

FIG. 15 illustrates an embodiment for transporting multiple packaging members of the present invention.

FIGS. 15A and 15B illustrate an embodiment of a packaging member in an assembled position.

FIGS. 16, 16A and 16B are end views of embodiments of the packaging member of the present invention in an unassembled position.

FIGS. 17 and 17A illustrate embodiments for transporting multiple packaging members of the present invention.

FIG. 18 is an end view of an embodiment of a packaging member of the present invention in an assembled position.

FIG. 19 is an end view of an embodiment of a packaging member of the present invention in an unassembled position.

FIG. 20 illustrates an embodiment of an arrangement of material plies in a packaging member.

FIG. 21 is an embodiment of a material ply.

FIGS. 22-24 illustrate additional embodiments of arrangements of material plies in packaging members.

FIGS. 25 and 25A illustrate additional embodiments of packaging members in unassembled positions.

FIGS. 26 and 26A illustrate packaging members in assembled positions of FIGS. 25 and 25A, respectively.

FIGS. 27 and 27A illustrate embodiments for transporting multiple packaging members of FIGS. 25 and 25A, respectively, of the present invention.

Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 illustrates a packaging member 10 for protecting an article (not shown) that is placed inside packaging member 10 prior to transporting the article. Packaging member 10 includes an opposed pair of rigid members 12, 14, commonly referred to as corner posts, angles or L-shaped members. Angles or L-shaped members 12, 14 each have a pair of respective legs 16, 18 and 20, 22. It is to be understood that the legs of L-shaped members can be of identical widths or different widths. Each pair of legs 16, 18 and 20, 22 are substantially perpendicular to one another, are of rigid construction with one another and have an L-shaped cross section along their length. The legs 16, 18 and 20, 22 collectively define the structural sides of packaging member 10 when assembled. Referring to FIGS. 1-3, angle 12 has an inner surface 30, outer surface 32 and legs 16, 18. Angle 14 has an inner surface 34, outer surface 36 and legs 20, 22. In one embodiment, an external member applied to an outer surface, such as a hinge 24, is secured to the outer surface 36 of angle 14 substantially adjacent to end 42 of leg 20 and is secured to outer surface 32 of angle 12 substantially adjacent to end 38 of leg 16. Ends 38 and 42 of legs 16 and 20 are separated by a gap 46 prior to assembly of the packaging member 10. In one embodiment, legs 16 and 20 can be a single leg, forming a U-shaped member, in which hinging can be brought about by a discontinuity formed directly in the leg, such as a score 152 (FIG. 11) or cut 154 (FIG. 12) formed therein that permits hinging.

In order to save space, when transporting empty packaging members, it is desirable to place multiple packaging members in a nested, unfolded or unassembled arrangement. As used herein, the terms unfolded or unassembled are intended to include orientations between angle 12, 14 in addition to those in which leg 20 of angle 14 and leg 16 of angle 12 are parallel to each other. For example, as shown in FIG. 15, leg 20 of angle 14 and leg 16 of angle 12 which together resemble a U-channel are disposed at an orientation angle A from each other. The magnitude of orientation angle A is sufficient to account for the inward offset that occurs due to stacking of packaging members. In other words, properly configured orientation angles A, which are a function of the thickness of the legs of the angle 12, 14 and combined length of legs 16 and 20 of respective angles 12, 14, permit nesting of each of the corresponding portions of adjacent packaging members. That is, the corresponding surfaces of each of the legs of adjacent nested packaging members can be maintained in abutting contact therewith. Upon assembly, packaging members have enhanced structural strength and rigidity by virtue of the two rigid angles.

As shown in FIGS. 15A and 15B, an embodiment of angle 14 and angle 12 that is transportable as shown in FIG. 15, leg 20 of angle 14 is of sufficient length so that angle 12 can be rotated toward leg 20. By further rotating angle 12 toward leg 20 until leg 18 of angle 12 abuts leg 20, or in one embodiment, leg 18 abuts the juncture between legs 20, 22 of angle 14, legs 16, 18 of angle 12 and leg 20 of angle 14 forms an enclosed region 28 when assembled, providing enhanced structural strength. In a further embodiment, leg 18 abuts leg 22 at any position along the length of leg 22, forming enclosed region 28. As further shown in FIG. 15B, which shows a perspective view of angles 12 and 14 in an assembled position ready for use, such as fastened to a corner of a pallet 78, a removed portion 76 from each of legs 16, 18 of angle 12 permits angle 12 to rotate with respect to pallet 78 and angle 14 to achieve enclosed region 28. It is appreciated that the angle 14 and angle 12 construction as shown in FIG. 15A may be secured to the corners of a pallet 78 after placing an article, such as an appliance (not shown) onto the pallet 78 and then applying a layer of plastic wrap (not shown) as is known in the art around the loaded pallet construction. The resulting loaded pallet construction has sufficient structural strength for loading in the vertical direction, by virtue of the assembled angle 12, 14 construction with enclosed region 28 for pallet stacking, increasing warehousing space. In addition, such loaded pallet construction provides visual evidence of damage to the appliance, thereby decreasing costs associated with handling appliances. That is, damaged appliances are less likely to be shipped to a customer, requiring subsequent return and replacement of the appliance.

An alternate packaging member construction is shown in FIGS. 16 and 17 in packaging member 250, which includes leg 20 having at least one discontinuity, such as notch 162, to form a hinged connection defining an enclosed region (shown with dotted lines in FIG. 16) for securing an article therein as will be discussed in additional detail below. In an alternate embodiment, shown in FIG. 16A, packaging member 250 may be configured to form a U-shaped member (shown with dotted lines in FIG. 16A). Discontinuities, as used herein, include notches, slots, perforations, creases or other features formed in a leg or material connecting different portions of a leg to permit a hinged connection of the leg along the feature. For example, as shown in FIG. 16B for a packaging member 275, at least one portion of leg 20 may be composed of a separate leg 21, containing a discontinuity 162 therebetween. That is, for one ply, legs 20, 22 are constructed from a single contiguous piece of material, with the shortened legs 20 of the remaining plies including corresponding separate plies, leg 21, separated by discontinuity 162. It is appreciated by those skilled in the art that if only one discontinuity, e.g., notch 162, is formed in leg 20, the enclosed region that can be formed is triangular, such as shown in FIG. 16A. In alternate embodiments, more than two discontinuities may be formed in one or both of legs 20, 22 to form enclosed regions. In a further alternate embodiment, legs 20, 22 may be brought toward one another, but not into contact with each other, i.e., a space or distance is maintained between legs 20, 22, so that an enclosed region is not formed. It is contemplated that in addition to forming enclosed regions having more sides than a triangle, one or more of the portions of legs 20, 22 can overlap, thereby providing additional combined material thickness and support for the assembled packaging members. For example, in an alternate embodiment, packaging member 300 can have overlapping legs 310, 320 or an overlapping region 72 as shown in FIG. 18. In another embodiment as shown in FIG. 19, the ends of legs 20, 22 are configured with corresponding notches 74, 75 that are brought into engagement when legs 20, 22 are directed toward each other and into contact with one another to define an enclosed region for packaging member 400. As shown in FIG. 17, packaging members 250 can be transported together. The corresponding surfaces of each of legs 20 and 22 of adjacent nested packaging members 250 can be maintained in abutting contact therewith, forming a group of nested members 260. In an alternate arrangement, as shown in FIG. 17A, a second group of nested members 265 is nested with the group of nested members 260. In addition to groups of nested members 260, 265, single packaging members 250 may additionally be arranged for transport. It is appreciated that multiple arrangements of groups may be used to minimize the amount of space required to transport the nested member groups. Upon assembly, packaging members 250 have enhanced structural strength and rigidity by virtue of the rigid construction by the junction of legs 20 and 22.

Referring to FIGS. 1-3, to assemble packaging member 10, angle 12 is rotated with respect to angle 14 about an axis 48 along hinge 24, preferably defined by the intersection of outer surface 36 and end 42 of leg 20 as will be discussed in additional detail below. This rotation of angle 12 brings end 38 into contact with the inner surface 34 of angle 14 substantially adjacent to end 42 of leg 20, forming a corner 52 and also brings inner surface 30 adjacent end 40 of leg 18 into contact with end 44 of leg 22, forming a corner 54 that is opposite to corner 52. Alternately, angle 14 can be rotated with respect to angle 12 to assemble packaging member 10. At this point, inner surfaces 30, 34 of respective angles 12, 14 define a rectangular enclosed region 28 for protecting an article placed therein. The article is preferably placed on an angle 12, 14 prior to rotating the other angle 14, 12. To maintain the position of angles 12, 14 once an angle 12, 14 has been rotated, flap 26 which is separately secured to outer surface 32 of angle 12 adjacent to end 40 of leg 18 is rotated about an axis 50 preferably located at the junction of outer surface 32 of angle 12 and end 40 of leg 18 until flap 26 contacts outer surface 36 of angle 14 adjacent to end 44 of leg 22. A bonding substance 56, such as adhesive, is provided along flap 26 to secure flap 26 to outer surface 36 of angle 14 substantially adjacent to end 44 of leg 22, thereby providing an efficient, stable packaging member 10 for transporting articles therein. Optionally, in addition to or in place of flap 26, tape, straps, or other securing materials may also be employed to secure packaging member 10 in its closed or assembled condition. Although not shown, the opposed open ends of packaging member 10 may be sealed or plugged by blocks, such as wood, or any available material suitable for this purpose.

Further referring to FIGS. 1-3, angles 12, 14 are now discussed. Angles 12, 14 are preferably formed by bonding layers (not shown) of paperboard together that have a preselected width and length corresponding to the desired width (horizontal distance) and height (vertical distance) of the legs of the angle and length (depth) of the angle. A bend, preferably of ninety degrees is then placed in the bonded layers or paperboard to produce angles 12, 14 having substantially L-shaped cross sections and a rigid construction. The composition of the angle 12, 14 may include any material that may be formed into a substantially rigid L-shaped cross section. Preferably legs 16, 22 and legs 18, 20 of respective angles 12, 14 are of substantially the same span (width or height), thereby forming a rectangle when the packaging member 10 is assembled. The rectangular shape of packaging member 10 provides a stable structure amenable to efficient stacking In addition to the stable shape, if the corresponding leg spans of angles 12, 14 are substantially equal, a single angle piece or component can be manufactured and then used for either angle 12 or 14. However, to accommodate the shape of an article, legs 16 and 22, as well as legs 18 and 20 can be formed of different spans, so long as one angle 12, 14 can rotate to the other angle 14, 12 to assemble the packaging member 10 similar to that shown in FIG. 2. Preferably, the thicknesses of angles 12, 14 range from about 0.060 inches to about 0.500 inches, and the preferred rectangular constructions include 2 inches wide by 2 inches high, or 2″×2″, as well as 3″×3″, 4″×4″, 1″×3″, 2″×4″ and 3″×5″. However, other thicknesses and constructions may be employed which may be significantly larger or smaller than the preferred size ranges, such limitations being imposed by the capabilities of the particular machine utilized to form the angles. While the angles are shown having flat or “squared” ends, it is understood that any shape which permits the angles to be brought into a closed contact to form the packaging member, including tapered or even curved ends, may be used herein.

Hinge 24, which hingedly connects angle 12 to angle 14, is preferably constructed of a flexible layer, such as paper, tape, cloth or any flexible material that may be secured to the outer surface of an angle. Hinge 24 may be secured to the outer surface of an angle by employing adhesives, tape, bands, rivets, Velcro®, staples, nails, brads, nuts and bolts, application of heat and/or pressure or any other suitable technique or component to attach a flexible material layer to the outer surface of the angle, although it is also possible to attach the flexible layer to the inner surface of the angle. Preferably, hinge 24 includes a narrow strip of flexible material, such as illustrated in FIGS. 2 and 3, wherein one end of hinge 24 is secured along outer surface 36 of angle 14 adjacent to end 42 of leg 20 and the other end of angle 24 is secured along outer surface 32 of angle 12 adjacent to end 38 of leg 16. However, if desired, for reasons possibly including manufacturing convenience, the flexible material layer defining hinge 24 may be secured to any additional portion of angle 14, up to and including the entire span of outer surface 36 of angle 14 as shown in FIG. 4. In this construction, the flexible layer defining flap 26 is similarly secured to angle 12 up to and including the entire span of outer surface 32 of angle 12. Angle 12 can be rotated with respect to angle 14 prior to securing flap 26 to angle 14 to produce the packaging member 10, or angle 14 can be rotated with respect to angle 12 to achieve the same result. Although not shown, a single flexible member defining both hinge 24 and flap 26 may be secured to the entire span of outer surface 36 of angle 14 and to the entire span of outer surface 32 of angle 12, if desired. Alternately, referring to FIG. 5, a closing member 58, which combines the features of hinge 24 and flap 26 in a single span of flexible material, is secured along the entire span of outer surface 32 of angle 12, the portion of closing member 58 extending past end 40 in a direction away from angle 12 performing the function of flap 26, and the portion of closing member 58 extending past end 38 in a direction away from angle 12 performing the function of hinge 24. In other words, hinge 24 may extend in secured contact with any proportion of the outer surfaces of the angles so long as there is sufficient flexible material to permit operation as a hinge.

Flap 26, similar to hinge 24, is an external member applied to an outer surface of a leg of a structural element and constructed of a flexible layer that is preferably connected to the outer surface 32 of leg 18 of angle 12 or to outside surface 36 of leg 22 of angle 14. Upon assembly of packaging member 10, wherein angle 12 and angle 14 are rotated toward each other about an axis along hinge 24 as will be discussed in further detail below, leg 18 adjacent to end 40 of angle 12 is then brought into contact with leg 22 adjacent to end 44 of angle 14. Preferably, a portion of flap 26 is secured to the outer surface of one of the legs, such as surface 32 of leg 18, so that the remaining portion of flap 26 is loose, extending past the end 40 of leg 18. The loose portion of flap 26 that extends past the end 40 of leg 18 is then attached of the outer surface 36 of leg 22 of angle 14 that is adjacent to end 44 by bonding means 56 to secure packaging member 10 in its closed or assembled position. Optionally, in addition to or in place of flap 26, tape, straps, or other securing materials or methods previously discussed may also be employed.

Referring back to FIGS. 1-3, the rotation of angle 12 with respect to angle 14 shall be further discussed. Preferably, angle 12 is rotated about axis 48 as illustrated in FIGS. 1 and 3, axis 48 being illustrated in FIG. 3 as a point, since axis 48 extends along the length of angle 14, which is not shown in FIG. 3. In one embodiment of the packaging member 10, as illustrated by FIG. 3, a plane defined by outer surface 36 of leg 20 of angle 14 is coincident with a plane defined by outer surface 32 of leg 16 of angle 12. In this position, end 42 is preferably parallel to end 38 and separated from end 38 by gap 46 along hinge 24. Preferably, to avoid structurally damaging hinge 24 due to excessive tensile loading, during or subsequent to assembly of packaging member 10, gap 46 is at least equal in width to the thickness of leg 20. Further, along gap 46 during the rotation of angle 12, hinge 24 remains substantially straight and the flexible material of hinge 24 overlying gap 46 also remains substantially coincident with the plane defined by outer surface 32 of leg 16 of angle 12. Therefore, as angle 12 is rotated about axis 48 in a direction toward angle 14, edge 60, which is defined by the intersection of outer surface 32 and end 38 of leg 16 of angle 12, traces the path of an arc having a radius substantially equal to gap 46. Edge 60 continues to trace this arc as angle 12 is further rotated about axis 48 until edge 60 is substantially coincident with edge 62, which is defined by the intersection of inner surface 34 and end 42 of leg 20 on angle 14. In this position, end 38 rests upon inner surface 34 adjacent to end 42. FIG. 2 illustrates the locations of the elements in this embodiment after the rotation of angle 12 is completed which defines corner 52 as previously discussed. Alternately, angle 14 can be rotated about axis 48 with respect to angle 12 to achieve identical results.

Alternately, referring to FIGS. 3 and 8, a rotation axis 64 may be employed to rotate angle 12 as discussed above. Axis 64 is defined by the intersection of outer surface 32 and end 38 of leg 16 on angle 12 and is illustrated as a point in FIGS. 3 and 8, for the same reasons as previously discussed for axis 48. In this embodiment, as angle 12 is rotated about axis 48, an edge 66, which is defined by the intersection of inner surface 30 and end 38 of leg 16, traces an arc having a radius substantially equal to the thickness of angle 12. An inner surface 23 of hinge 24 remains substantially coincident with outer surface 36 of leg 20 as angle 12 is rotated. Edge 66 continues to trace this arc as angle 12 is further rotated about axis 64 until edge 66 is substantially coincident with an edge 68, which is defined by the intersection of outer surface 36 and end 42 of leg 20 on angle 14. In this position, end 38 rests upon the portion of inner surface 23 of hinge 24 defined by gap 46 (FIG. 3) that is substantially coincident with outer surface 36 of leg 20. End 42 abuts inner surface 30 of angle 12 adjacent end 42 of leg 16. FIG. 8 provides an enlarged view illustrating the locations of the elements of this embodiment after the rotation of angle 12 is completed thereby defining corner 70, which is similar to corner 52, discussed in detail above. FIG. 9 illustrates an embodiment wherein corresponding legs 18, 20 and 16, 22 of angles 12, 14 have a substantially equal span. One difference between FIG. 2 and FIG. 9 is the relative positioning of ends 38, 40 of angle 12 with respect to ends 42, 44 of angle 14. In FIG. 2, end 40 is positioned above and abuts end 44 and end 42 horizontally abuts the end portion of leg 20 adjacent end 42. In FIG. 9, end 40 horizontally abuts leg 22 adjacent end 44 and end 42 horizontally abuts the end portion of leg 16 adjacent end 38. Although the FIG. 9 embodiment is equally workable as the embodiment in FIG. 2, the FIG. 9 embodiment may be less desirable than the preferred embodiment illustrated in FIG. 2 in that the embodiment in FIG. 9 can have a reduced ability to support external vertical loading, especially if the external vertical load is concentrated on leg 18 adjacent to end 40. For this loading condition, structural support is provided primarily by hinge 26, as opposed to the supporting arrangement in FIG. 2, in which leg 22 is directly beneath end 40 and provides additional vertical structural support. If additional vertical support is required while maintaining corner 70, the embodiment shown in FIG. 9A may be more effectively employed. In FIG. 9A, leg 16 of angle 12 is longer than leg 22 of angle 14 by the thickness of leg 20 of angle 14. Similarly, leg 18 of angle 12 is longer than leg 20 of angle 14 by the thickness of leg 22 of angle 14. While this embodiment provides additional vertical support for reacting to vertical loads applied to leg 18, the span of the legs of angles 12 and 14 are now different, which requires the manufacturing of different angles.

FIG. 6 illustrates an alternate embodiment of the packaging member. Packaging member 100 includes a substantially U-shaped member 102 having a base 104 with legs 106, 108 preferably extending upwardly parallel from opposed ends of base 104. Legs 106, 108 have respective ends 114, 116 for supporting a substantially flat or planar member 120 having opposed ends 122, 124. U-shaped member 102 and flat member 120 have an outer surface 112 and an inner surface 110 which defines an enclosed region 126 for securing the article therein. Hinge 118 is preferably secured to the outer surface 112 of U-shaped member 102 adjacent to end 116 of leg 108 and to the outer surface 112 of flat member 120 adjacent to end 122 for hingedly connecting flat member 120 to leg 108 of U-shaped member 102. Hinge 118 is otherwise similar to hinge 24 as previously discussed. Hinge 118 can also be secured to the inner surface 112. After the article is placed within U-shaped member 102, flat member 120 is rotated with respect to U-shaped member 102 about an axis along hinge 118 until ends 122, 124 of flat member 120 are supported by respective ends 114, 116 of legs 106, 108. Although a flap similar to that employed in FIG. 2 should not be necessary to secure flat member 120 in the closed or assembled position, a bonding means 128, as previously discussed, may optionally be employed.

In another emodiment as shown in FIG. 7, a discontinuity such as a score 130, or a V-shaped notch as shown in FIG. 7, may be formed in flat member 120 adjacent to end 124 so that an applied force (not shown) substantially perpendicular to outer surface 112 at end 124 can form a portion 132 that extends substantially perpendicularly to the plane defined by outer surface 112 of flat member 120. Portion 132 has an outer surface 112 and an extension surface 134. With flat member 120 in its closed position and supported by U-shaped member 102, extension surface 134 of portion 132 preferably abuts the outer surface 112 of the U-shaped member 102 adjacent to end 128 of leg 106 to further secure flat member 120 in place. To even further secure flat member 120, bonding means 128, similar to those employed to secure hinge 24, can also be used. Similarly achieving the collective shape defined by flat member 120 and portion 132, an angle may be formed with a leg having the desired span of portion 132. Referring to FIG. 10, flat member 120 may have opposed notches 136 formed adjacent ends 122, 124 defining opposed surfaces 138 for abutting legs 106, 108 adjacent respective ends 114, 116 along inner surface 110 for forming a more secure connection with legs 106, 108 of flat member 120.

Referring to FIGS. 11-14, it is apparent that forming a discontinuity such as a score 152 (FIG. 11), or a V-shaped notch, along an inside surface of a web 159 having opposed ends extending into legs 156, 158 of U-channel 150 in a manner similar to that described in FIG. 7 for folding portion 132, may produce hinged angles of the present invention. In other words, an embodiment of the present invention may be achieved by folding along an axis defined by score 152, in effect a hinged connection, so that the enclosed region of the resulting packaging member is defined by legs 156, 158, with adjacent segments of web 159 effectively forming the other two legs of the packaging member. Similarly, another embodiment may be achieved by forming a discontinuity such as a cut 154, or back score, in an outside surface 155 of web 159 having opposed ends extending into legs 156, 158 of U-channel 150. Alternately, as shown in FIG. 13, a combination of discontinuities such as a groove 162 and a cut 164 may be employed to achieve the desired hinging effect, possibly depending upon the material composition and thickness of the U-channel being manipulated. Although not shown, optional flap members similar to flap 26 previously discussed may be used to secure the packaging member in its closed or assembled position, although tape, straps, or other securing materials or methods previously discussed may also be employed. While it is contemplated that multiple grooves/cuts may be formed in an angle member to achieve the packaging member, or even forming three grooves/cuts in a flat member that define respective axes for folding the flat member to form a rectangular packing member, a degree of structural stiffness inherent with an embodiment employing a single groove/cut in a U-channel is forfeited. It is also contemplated that a single groove/cut may be formed in a surface of an angle member, or an aligned pair of grooves/cuts may be formed on opposed surfaces of an angle member to achieve a packaging member that defines a triangle.

One skilled in the art can appreciate that in addition to variations of shape and material composition, hinges and flaps may be located anywhere along the thickness of the angles. In other words, a flexible layer may be secured along the inner surface of the angles and may be formed anywhere between the inner and outer surfaces, including being formed from the same material being used to construct the angles themselves. In other words, the hinge may extend from any position or portion of one end of an angle to any position or portion of the corresponding angle, not being limited to the outer surfaces of respective angle members. Additionally, it is apparent that inclusion of the flap is optional, especially if adhesive, tape, straps or other means of securing the angles in affixed position are employed.

As shown in FIGS. 20-23, packaging member 200 is configured to protect edges or corners of an article (not shown), such as during transportation of the article. These packaging member embodiments save material costs, while substantially maintaining structural strength and rigidity. In one embodiment, as shown in FIG. 20, packaging member 200 includes a leg 202 and a leg 204 disposed at a predetermined angle to each other, such as 90 degrees, along a junction 206. Material plies 208, 216 and 218, as shown in FIG. 20, are integrally connected along junction 206. An exemplary material ply, such as material ply 208 as shown in FIG. 21, defines a bend 210 having a width 212 to the left hand side of bend 210 and a width 214 to the right hand side of bend 210. As shown, width 212 has a different magnitude than width 214. In other words, bend 210 is not disposed at a substantially centered position with respect to widths 212, 214.

FIG. 20 includes an embodiment of a packaging member 200 having legs 202, 204 each having, for example, respective lengths of 3 inches, or a 3″×3″ construction. It is to be understood that legs of packaging members can have different lengths and that the length of one leg can be different from the other leg. As further shown in FIG. 20, the left and right hand portion (LHP, RHP) widths of the exposed, i.e., outer material ply 208 can be, for example, 2 inches and 3 inches in width, respectively. For example, as further shown in FIG. 21, material ply 208 has a LHP width 212 of 2 inches and a RHP width 214 of 3 inches, separated by bend 210.

As further shown in FIG. 20, a second material ply 209 is adjacent to outer material ply 208. The second material ply 209 can be, for example, 3 inches (LHP) and 2 inches (RHP) or reversed in orientation from the outer material ply 208. In other words, the plies of the pair of material plies 208, 209 are alternately disposed, or reversed along junction 206. As used herein, “alternately disposed” is not limited to mean that adjacent material plies must strictly follow a reversed orientation. That is, multiple adjacent plies can have similar orientation, but that in the overall arrangement of the material plies, at least two of the material plies are disposed in a reversed orientation. This definition of “alternatively disposed” is also intended to apply where there are material plies having different RHP, LHP lengths, thicknesses or other differences, such as material types, between the material plies. The next material ply adjacent to the second material ply 209 is material ply 216 which can be, for example, 1 inch (LHP) and 3 inches (RHP) with the following adjacent material ply 217 reversed, from material ply 216, i.e., having a 3 inch (RHP) and a 1 inch (LHP), for example. Finally, an inner material ply layer 218 which can be, for example, 3 inches (LHP) and 3 inches (RHP) is disposed adjacent to material ply 217. In an alternate embodiment, material layer 218 defines the outer material layer. As used in FIGS. 20-24, the term inner material ply identifies the material ply that is in contact with or adjacent to the article being protected. Conversely, the term outer material ply identifies the material ply that is opposite the article being protected.

FIG. 22 shows an embodiment of packaging member 200 comprising a plurality of alternately disposed material plies 216. It is appreciated that in an embodiment of material plies 216 having 3 inch and 1 inch portions, the amount of savings of material is 33% when compared to a packaging member having 3 inch by 3 inch portions, while maintaining material ply thickness adjacent junction 206.

FIG. 23 shows an embodiment of packaging member 200 comprising an outer material ply 220 disposed adjacent to a first material ply 222, which first material ply 222 is disposed adjacent to a second material ply 224. The second material ply 224 is alternately disposed from the first material ply 222. Material ply 226 is disposed adjacent to the second material ply 224. Outer material ply 220 can be similar to inner material ply 218 of FIG. 20. First material ply 222 can be similar to second material ply 224 and material ply 226, but each of material plies 222, 224, 226 can be sized differently.

FIG. 24 shows an embodiment of packing member 200 similar to FIG. 23, except for the addition of inner ply 228 disposed adjacent to material ply 226. As shown inner and outer material plies 220, 228 can be similar, and in one embodiment, the LHP and RHP widths of inner and outer plies can be the same.

It is to be understood that although material ply pairs 224 and 226 are adjacent to each other, many combinations of arrangement and orientation of material plies are possible, including a combination of material layers that are each differently sized and/or having different thickness, and/or different material type. Although material plies are shown in which the longer width of each material ply substantially corresponds to the length of the legs of the packaging member, the material ply widths are not limited to such constructions, as either or both of left and right hand portion widths of at least one material ply can be less than the leg lengths of the packaging member. A benefit of such material plies having reduced width portions results in greater material savings, although such savings must be balanced by a reduction in strength of the resulting packaging member.

Referring to FIG. 25, an alternate embodiment of a packaging member 500 includes an angle 514 having legs 520 and 522, an angle 528 having legs 530 and 532, and an angle 534 having legs 536 and 538. Leg 522 of angle 514 is hingedly connected to leg 530 of angle 528 by a discontinuity 524, and leg 536 of angle 534 is hingedly connected to leg 520 of angle 514 by a discontinuity 526. Each pair of legs 520, 522, legs 530, 532 and legs 536, 538 are substantially perpendicular to one another, are of rigid construction with one another and have an L-shaped cross section along their length. In an alternate embodiment, as shown in FIG. 25A, an additional discontinuity 525 is formed at the junction of legs 520, 522, so that the packaging member is in the form of a U-shaped member, so that legs 520, 522 are not components of a rigid angle (i.e., angle 514). FIG. 26 shows packaging member 500 in an assembled position in which leg 532 of angle 528 is brought toward angle 514 and into abutment with angle 514 via discontinuity 524, and leg 538 of angle 534 is brought toward angle 514 and into abutment with angle 514 via discontinuity 526 when assembled. Angle 528 and leg 522 form an enclosed region 542 and angle 534 and leg 520 form an enclosed region 544. As shown in FIG. 26, the ends of legs 532 and 538 substantially coincide with the junction between legs 520 and 522 of angle 514. When assembled, packaging member 500 provides enhanced stacking strength, such as when used as a corner member on a pallet as previously described with FIGS. 15A and 15B.

FIG. 26A, similar to FIG. 26, shows the embodiment of packaging member 500 of FIG. 25A in an assembled position. The ends of legs 532 and 538 substantially coincide with the junction between legs 520 and 522 of angle 514. When assembled, packaging member 500 provides enhanced stacking strength, such as when used as a corner member on a pallet as previously described with FIGS. 15A and 15B.

In order to save space, when transporting empty packaging members, it is desirable to place multiple packaging members in a nested, unfolded or unassembled arrangement. As shown in FIG. 27, leg 530 of angle 528 and leg 522 of angle 514 which together resemble a U-channel are disposed at an orientation angle B from each other. Similarly, as further shown in FIG. 27, leg 520 of angle 514 and leg 536 of angle 534 which together resemble a U-channel are disposed at an orientation angle C from each other. The magnitude of orientation angles B and C is sufficient to account for the inward offset that occurs due to stacking of packaging members. In other words, properly configured orientation angles B and C, which are a function of the thickness of the legs of the angles 528, 514 and combined length of legs 530 and 522 of respective angles 528, 514 for angle B, and which are a function of the thickness of the legs of the angles 514, 534 and combined length of legs 520 and 536 of respective angles 514, 534 for angle C, permit nesting of each of the corresponding portions of adjacent packaging members 500. That is, the corresponding surfaces of each of the legs of adjacent nested packaging members 500 can be maintained in abutting contact therewith. Upon assembly, packaging members 500 have enhanced structural strength and rigidity by virtue of the three rigid angles 514, 528, 534 and enclosed regions 542, 544.

FIG. 27A shows a space-saving arrangement of empty packaging members of FIG. 25A. As further shown in FIG. 27A, the combined span of leg 530 of angle 528 and leg 522 and the combined span of leg 520 leg 536 of angle 534, which together resemble a U-channel, are disposed at an orientation angle D from each other.

The magnitude of orientation angle D is sufficient to account for the inward offset that occurs due to stacking of packaging members. In other words, properly configured orientation angle D, which are a function of the thickness of the legs of the angles 528, 514 and combined the combined spans of leg 530 of angle 528 and leg 522 as well as leg 520 and leg 536 of angle 534 for angle B, permit nesting of each of the corresponding portions of adjacent packaging members 500. That is, the corresponding surfaces of each of the legs of adjacent nested packaging members 500 can be maintained in abutting contact therewith. Upon assembly, as shown in FIG. 26A, packaging members 500 have enhanced structural strength and rigidity by virtue of the two rigid angles 514 and 528 and enclosed regions 542, 544.

While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. 

1. A packaging member comprising: a substantially planar first leg, the first leg having a plurality of paperboard layers bonded together; a substantially planar second leg connected to the first leg, the second leg being positioned substantially perpendicular to the first leg, the second leg comprising at least one continuous paperboard layer, the second leg comprising: a first leg portion, a second leg portion and a third leg portion; each of the first leg portion, the second leg portion and the third leg portion comprising the at least one continuous paperboard layer and a plurality of additional paperboard layers bonded together; a first space positioned between the plurality of additional paperboard layers of the first leg portion and the plurality of additional paperboard layers of the second leg portion; and a second space positioned between the plurality of additional paperboard layers of the second leg portion and the plurality of additional paperboard layers of the third leg portion.
 2. The member of claim 1 wherein the first leg and the second leg are connected by a continuous curved joint.
 3. The member of claim 2 wherein the first leg comprises the at least one continuous paperboard layer.
 4. The member of claim 3 wherein the first leg portion of the second leg is adjoining the first leg and the first leg comprises the plurality of additional paperboard layers of the first leg portion.
 5. The member of claim 1 wherein the first space is one of a notch or a slot in the second leg and the second space is one of a notch or a slot in the second leg.
 6. The member of claim 1 wherein: the first leg portion of the second leg is adjoining the first leg; the third leg portion of the second leg is positioned opposite the first leg portion; and in response to the first leg and the second leg being directed toward each other, the third leg portion of the second leg is directed into contact with the first leg to define an enclosed region for securing an article therein.
 7. The member of claim 1 wherein: the at least one continuous paperboard layer and the first space operate a hinge between the first leg portion and the second leg portion; and the at least one continuous paperboard layer and the second space operate a hinge between the second leg portion and the third leg portion.
 8. The member of claim 1 wherein the first leg and the second leg are configured and positioned to receive a corresponding first leg and second leg of a second member to permit the second member to be nested with the member.
 9. The member of claim 8 wherein a planar portion of the first leg is in abutting contact with the corresponding first leg of the second member and a planar portion of the second leg is in abutting contact with the corresponding second leg of the second member upon the second member being nested with the member.
 10. A packaging member for securing an article comprising a preformed laminated paperboard member having a preselected length, the member having at least two paperboard layers bonded together, the member having a first substantially planar leg and a substantially planar second leg joined by a continuous curved joint therebetween forming a substantially L-shaped cross section across the length of the member; the joint providing an integral and rigid construction between the first leg and the second leg of the substantially L-shaped cross section; the first leg having at least one substantially parallel discontinuity formed substantially along the preselected length of the member, each discontinuity forming at least two adjacent leg portions connected together; in response to the first leg and the second leg being directed toward each other, one of the at least two adjacent leg portions is directed into contact with the second leg to define an enclosed region having one rigid corner defined by the continuous curved joint for securing an article therein; wherein the packaging member can be nested with additional packaging members in an unassembled position, and wherein a substantial portion of each of the corresponding surfaces of first and second legs of adjacent nested packaging members can be maintained in substantially uninterrupted abutting contact.
 11. The packaging member of claim 10 wherein the preformed member further comprises a third leg opposite the second leg, the first leg and a third leg forming a substantially L-shaped cross section of rigid construction across the length of the member; the at least two adjacent leg portions forming an angled joint in the first leg in response to the third leg and the second leg being directed toward each other and into contact with one another to define an enclosed region for securing an article therein; wherein multiple packaging members can be nested in an unassembled position, and wherein corresponding surfaces of adjacent first, second and third nested legs of adjacent packaging members can be maintained in abutting contact.
 12. The packaging member of claim 10 wherein each discontinuity is formed in at least one of an outer surface of the first leg or an inner surface of the first leg.
 13. The packaging member of claim 10 wherein the second leg has at least one substantially parallel discontinuity formed along the preselected length of the member; each discontinuity forming at least two adjacent leg portions connected together; one of the at least two adjacent leg portions of the second leg is directed toward the first leg to define a distance between the first and second leg in response to the first and second leg being directed toward each other.
 14. The packaging member of claim 13 wherein each discontinuity is formed in at least one of an outer surface of the second leg or an inner surface of the second leg.
 15. The packaging member of claim 10 wherein one group of nested packaging members are nested with another group of nested packaging members.
 16. The packaging member of claim 15 wherein a surface of one of the first and second legs of one group of nested packaging members abuts a corresponding surface of one of the first and second legs of the other group of nested packaging members.
 17. The packaging member of claim 10 wherein at least one leg portion of the first leg overlaps at least a segment of the other leg.
 18. A packaging member for securing an article comprising a member having a preselected length, the member having at least two paperboard layers bonded together, the member having a first substantially planar leg and a second substantially planar leg joined by a continuous joint therebetween forming a substantially L-shaped cross section across the length of the member; the joint providing an integral and rigid construction between the first leg and the second leg of the substantially L-shaped cross section; the first leg having a substantially parallel discontinuity formed substantially along the preselected length of the member, the discontinuity forming two adjacent leg portions forming an angled joint in the first leg in response to the first leg and the second leg being directed toward each other to define a distance between the first and second leg; an assembled position of the member having one rigid corner defined by the continuous curved joint and the angled joint; wherein a first group of multiple packaging members can be nested in an unassembled position, and wherein a substantial portion of each of the corresponding surfaces of first and second legs of adjacent nested packaging members can be maintained in substantially uninterrupted abutting contact.
 19. The packaging member of claim 19 wherein the second leg has at least one substantially parallel discontinuity formed along the preselected length of the member; each discontinuity forming at least two adjacent leg portions connected together; one of the at least two adjacent leg portions of the second leg is directed toward the first leg to define an enclosed region for securing an article therein. 